The Experts below are selected from a list of 60777 Experts worldwide ranked by ideXlab platform
Yanming Zhang - One of the best experts on this subject based on the ideXlab platform.
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reduction of energy consumption and Thermal Deformation in wedm by magnetic field assisted technology
International Journal of Precision Engineering and Manufacturing-Green Technology, 2020Co-Authors: Yanming Zhang, Zhen Zhang, Guojun ZhangAbstract:Energy consumption and machining accuracy are considered to be two important attributes of performance indicators for green operations of wire electric discharge machining (WEDM). However, there is a paucity of studies that focus on the energy consumption and geometric error caused by Thermal Deformation. In this paper, a hybrid technique of WEDM with assisted magnetic field (MF) is proposed for enhancing machining performance to reduce energy consumption and Thermal Deformation. Based on the principles of Thermal Deformation, energy consumption, and magnetic field-assisted WEDM, a set of experiments is conducted to investigate Thermal Deformation and energy consumption of MF-assisted WEDM and conventional WEDM machining of Inconel 718. The effects of magnetic field on Thermal Deformation, discharge waveforms, surface integrity, and energy consumption are analyzed, and it is concluded that the proposed hybrid technique of MF-assisted WEDM offers numerous advantages and potential for applications in the green precision manufacturing field.
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analysis and reduction of process energy consumption and Thermal Deformation in a micro structure wire electrode electric discharge machining thin wall component
Journal of Cleaner Production, 2020Co-Authors: Guojun Zhang, Yanming Zhang, Yu Huang, Zhen Zhang, Zhi ChenAbstract:Abstract In order to reduce process energy consumption and geometric error induced by Thermal Deformation simultaneously in sustainable wire electrode discharge machining(WEDM) process, this work applies a new micro crack wire electrode to enhance machine characteristic, and describes the reduction mechanism of above two critical factors compared with brass wire when machining thin-wall components. Firstly, a number of experiments are conducted to explore the effects trend of machining parameters on Thermal Deformation and material removal rate(MRR) by above two wire tools. The results indicate that micro crack wire can achieve a significant decrease by an average of 32.60% in MRR and 42.69% in Thermal Deformation compared with brass wire. And the best parameters combination for micro crack wire is pulse on time:13 μs、pulse off time:8 μs、wire speed:0.09 m/s、water pressure:1.1 MPa. The analysis of residual stress and discharge points distribution explains the improvement mechanism of micro crack wire by decreasing the magnitude of residual stress (33.14% on average) and non-uniformity of discharge points distribution (36.32% on average). Besides, the results of energy consumption and environmental effect demonstrate that micro crack wire can obviously reduce energy consumption by an average of 22.68% and debris pollution. Eventually, the analysis of surface topography, debris shape, micro structures, recast layer thickness and surface element composition are also performed. It can be concluded that the micro crack wire shows prominent superiority and potential for applications in the sustainable manufacturing field.
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simulation and experimental investigations of complex Thermal Deformation behavior of wire electrical discharge machining of the thin walled component of inconel 718
Journal of Materials Processing Technology, 2019Co-Authors: Yanming Zhang, Guojun Zhang, Zhen Zhang, Shiyi Guo, Hao Huang, Yu HuangAbstract:Abstract The geometric error is very important to the component performance in wire electric discharge machining (WEDM) process, yet few studies have focused on the geometric error caused by Thermal Deformation. This work mainly describes the complex Thermal Deformation phenomenon and its corresponding cause during the WEDM processing the thin-walled component of Inconel 718. Firstly, the thermo-physical model is developed to explore the Thermal Deformation by calculating the temperature distribution of workpiece and surface residual stress. Then a number of experiments are conducted to investigate the effect of pulse-on time, pulse current, water pressure, and wire speed on the Thermal Deformation of thin-walled samples. By the comparison of experimental and simulation results, it was confirmed the reliability and accuracy of thermo-physical model while experimental results revealed that the effects of process parameters of WEDM on the surface integrity as well as Thermal Deformation scale. Furthermore, we presented their variations of residual stress and surface characteristics including surface topography, micro-hardness, surface elemental composition, and recast layer thickness under different Thermal Deformation conditions. It can be concluded that the variations of residual stress and surface integrity are almost consistent with that of the Thermal Deformation.
Liangchi Zhang - One of the best experts on this subject based on the ideXlab platform.
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applied mechanics in grinding part 7 residual stresses induced by the full coupling of mechanical Deformation Thermal Deformation and phase transformation
International Journal of Machine Tools & Manufacture, 1999Co-Authors: Mofid Mahdi, Liangchi ZhangAbstract:In this final part of the series research on residual stresses in ground components, the full coupling of mechanical Deformation, Thermal Deformation and phase transformation during grinding was investigated using the finite element method. It was found that all the components of surface residual stresses become tensile when phase transformation takes place. This phenomenon is independent of the cooling conditions and type of grinding operations and is affected only slightly by the variation of surface mechanical traction. The distribution of the residual stress in grinding direction is nearly linear in both the martensite and non-martensite zones. However, the location of the maximum residual stress is related to the surface mechanical traction and depth of martensite transformation.
Fan Xuewu - One of the best experts on this subject based on the ideXlab platform.
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Ultra-thin carbon fiber mirrors: nickel plated, optical fabrication and Thermal Deformation test
Elsevier GmbH, 2019Co-Authors: Xu Liang, Xie Yongjie, Wang Yongjie, Ding Jiaoteng, Ma Zhen, Fan XuewuAbstract:The aperture of space remote sensing camera is increasing, and the demand for lighter weight is getting higher and higher. With the advancement of active optics, the thickness of optical components has gradually grown to light and thin. It is extremely difficult to develop ultrathin mirrors using brittle materials such as traditional optical glass and silicon carbide. Due to advantages such as low density, high specific stiffness, low Thermal expansion coefficient, toughness, and additive rapid manufacturing properties, carbon fiber reinforced plastic (CFRP) is one of potential applications for large-diameter ultra-thin mirrors. However, the carbon fiber composite material is a two-phase material that cannot be used as optical surface and must be surface-modified. In this paper, the surface modification of CFRP substrate was carried out by chemical nickel plating and nickel electroplating. The modified nickel layer covers all surfaces of CFRP substrate, and nickel layers satisfying the thickness, bonding force, and internal stress requirements. A Φ100 mm aperture ultra-thin carbon fiber mirror developed, after optical fabricating, its surface accuracy RMS is better than λ/15. Thermal Deformation analysis and test show that the Thermal Deformation of ultra-thin carbon fiber mirrors is mainly manifested by the change of radius of curvature, which is caused by the thickness error of the nickel layer on the front and rear faces. In addition, although Thermal Deformation caused by the lamination angle error of CFRP substrate is relatively small in value, it should still be given enough attention, because the astigmatic error produced is hard to eliminate. © 2018 Elsevier GmbH
Xuewu Fan - One of the best experts on this subject based on the ideXlab platform.
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ultra thin carbon fiber mirrors nickel plated optical fabrication and Thermal Deformation test
Optik, 2019Co-Authors: Yongjie Xie, Yongjie Wang, Jiaoteng Ding, Xuewu FanAbstract:Abstract The aperture of space remote sensing camera is increasing, and the demand for lighter weight is getting higher and higher. With the advancement of active optics, the thickness of optical components has gradually grown to light and thin. It is extremely difficult to develop ultrathin mirrors using brittle materials such as traditional optical glass and silicon carbide. Due to advantages such as low density, high specific stiffness, low Thermal expansion coefficient, toughness, and additive rapid manufacturing properties, carbon fiber reinforced plastic (CFRP) is one of potential applications for large-diameter ultra-thin mirrors. However, the carbon fiber composite material is a two-phase material that cannot be used as optical surface and must be surface-modified. In this paper, the surface modification of CFRP substrate was carried out by chemical nickel plating and nickel electroplating. The modified nickel layer covers all surfaces of CFRP substrate, and nickel layers satisfying the thickness, bonding force, and internal stress requirements. A Φ100 mm aperture ultra-thin carbon fiber mirror developed, after optical fabricating, its surface accuracy RMS is better than λ/15. Thermal Deformation analysis and test show that the Thermal Deformation of ultra-thin carbon fiber mirrors is mainly manifested by the change of radius of curvature, which is caused by the thickness error of the nickel layer on the front and rear faces. In addition, although Thermal Deformation caused by the lamination angle error of CFRP substrate is relatively small in value, it should still be given enough attention, because the astigmatic error produced is hard to eliminate.
Guojun Zhang - One of the best experts on this subject based on the ideXlab platform.
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reduction of energy consumption and Thermal Deformation in wedm by magnetic field assisted technology
International Journal of Precision Engineering and Manufacturing-Green Technology, 2020Co-Authors: Yanming Zhang, Zhen Zhang, Guojun ZhangAbstract:Energy consumption and machining accuracy are considered to be two important attributes of performance indicators for green operations of wire electric discharge machining (WEDM). However, there is a paucity of studies that focus on the energy consumption and geometric error caused by Thermal Deformation. In this paper, a hybrid technique of WEDM with assisted magnetic field (MF) is proposed for enhancing machining performance to reduce energy consumption and Thermal Deformation. Based on the principles of Thermal Deformation, energy consumption, and magnetic field-assisted WEDM, a set of experiments is conducted to investigate Thermal Deformation and energy consumption of MF-assisted WEDM and conventional WEDM machining of Inconel 718. The effects of magnetic field on Thermal Deformation, discharge waveforms, surface integrity, and energy consumption are analyzed, and it is concluded that the proposed hybrid technique of MF-assisted WEDM offers numerous advantages and potential for applications in the green precision manufacturing field.
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analysis and reduction of process energy consumption and Thermal Deformation in a micro structure wire electrode electric discharge machining thin wall component
Journal of Cleaner Production, 2020Co-Authors: Guojun Zhang, Yanming Zhang, Yu Huang, Zhen Zhang, Zhi ChenAbstract:Abstract In order to reduce process energy consumption and geometric error induced by Thermal Deformation simultaneously in sustainable wire electrode discharge machining(WEDM) process, this work applies a new micro crack wire electrode to enhance machine characteristic, and describes the reduction mechanism of above two critical factors compared with brass wire when machining thin-wall components. Firstly, a number of experiments are conducted to explore the effects trend of machining parameters on Thermal Deformation and material removal rate(MRR) by above two wire tools. The results indicate that micro crack wire can achieve a significant decrease by an average of 32.60% in MRR and 42.69% in Thermal Deformation compared with brass wire. And the best parameters combination for micro crack wire is pulse on time:13 μs、pulse off time:8 μs、wire speed:0.09 m/s、water pressure:1.1 MPa. The analysis of residual stress and discharge points distribution explains the improvement mechanism of micro crack wire by decreasing the magnitude of residual stress (33.14% on average) and non-uniformity of discharge points distribution (36.32% on average). Besides, the results of energy consumption and environmental effect demonstrate that micro crack wire can obviously reduce energy consumption by an average of 22.68% and debris pollution. Eventually, the analysis of surface topography, debris shape, micro structures, recast layer thickness and surface element composition are also performed. It can be concluded that the micro crack wire shows prominent superiority and potential for applications in the sustainable manufacturing field.
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simulation and experimental investigations of complex Thermal Deformation behavior of wire electrical discharge machining of the thin walled component of inconel 718
Journal of Materials Processing Technology, 2019Co-Authors: Yanming Zhang, Guojun Zhang, Zhen Zhang, Shiyi Guo, Hao Huang, Yu HuangAbstract:Abstract The geometric error is very important to the component performance in wire electric discharge machining (WEDM) process, yet few studies have focused on the geometric error caused by Thermal Deformation. This work mainly describes the complex Thermal Deformation phenomenon and its corresponding cause during the WEDM processing the thin-walled component of Inconel 718. Firstly, the thermo-physical model is developed to explore the Thermal Deformation by calculating the temperature distribution of workpiece and surface residual stress. Then a number of experiments are conducted to investigate the effect of pulse-on time, pulse current, water pressure, and wire speed on the Thermal Deformation of thin-walled samples. By the comparison of experimental and simulation results, it was confirmed the reliability and accuracy of thermo-physical model while experimental results revealed that the effects of process parameters of WEDM on the surface integrity as well as Thermal Deformation scale. Furthermore, we presented their variations of residual stress and surface characteristics including surface topography, micro-hardness, surface elemental composition, and recast layer thickness under different Thermal Deformation conditions. It can be concluded that the variations of residual stress and surface integrity are almost consistent with that of the Thermal Deformation.
